Abstract: A method of manufacturing a shim and related systems and equipment. A mechanical tool inserted into a shim space defined between two or more components with the mechanical tool in a first configuration. The mechanical tool is free of measurement electronics. The mechanical tool, while in the shim space, is modified such that the mechanical tool assumes a second configuration to establish a plurality of model points corresponding to a boundary surface of the shim space. The mechanical tool is removed from the shim space while maintaining the mechanical tool in the second configuration. Using a measurement station distinct from the tool, the positions of the model points are electronically measured while the mechanical tool is both disposed outside of the shim space and in the second configuration. Machining instructions are generated based on the measured positions. A shim is fabricated based on the generated machining instructions.

Abstract: A method of manufacturing a shim and related systems and equipment. A mechanical tool inserted into a shim space defined between two or more components with the mechanical tool in a first configuration. The mechanical tool is free of measurement electronics. The mechanical tool, while in the shim space, is modified such that the mechanical tool assumes a second configuration to establish a plurality of model points corresponding to a boundary surface of the shim space. The mechanical tool is removed from the shim space while maintaining the mechanical tool in the second configuration. Using a measurement station distinct from the tool, the positions of the model points are electronically measured while the mechanical tool is both disposed outside of the shim space and in the second configuration. Machining instructions are generated based on the measured positions. A shim is fabricated based on the generated machining instructions.

Abstract: An orbital drill bushing adapter for use with a drill unit. In one embodiment, the orbital drill bushing adapter comprises a main body and locking arms. The main body includes a base member having an upper surface, a lower surface, and an external side wall that extends between the upper surface and the lower surface. The main body further includes a cylindrical spacer that projects from the lower surface of the base member, and is configured to fit in a drill hole of an orbital drill bushing. The main body includes a cylindrical hole that passes through the base member and the cylindrical spacer. The locking arms are pivotally coupled to the base member, and are configured to clamp the main body onto the orbital drill bushing.

Abstract: An orbital drill bushing adapter for use with a drill unit. In one embodiment, the orbital drill bushing adapter comprises a main body and locking arms. The main body includes a base member having an upper surface, a lower surface, and an external side wall that extends between the upper surface and the lower surface. The main body further includes a cylindrical spacer that projects from the lower surface of the base member, and is configured to fit in a drill hole of an orbital drill bushing. The main body includes a cylindrical hole that passes through the base member and the cylindrical spacer. The locking arms are pivotally coupled to the base member, and are configured to clamp the main body onto the orbital drill bushing.

Abstract: A tool for rotating a first component of an assembly relative to a second component of the assembly is disclosed. The tool comprises a ring support, a first wrench, coupled to the ring support, a worm ring, rotationally coupled to the ring support, a second wrench, coupled to the worm ring, and a worm screw, rotationally coupled to the ring support and in mesh with the worm ring.

Abstract: A tool (100) for rotating a first component (210) of an assembly (200) relative to a second component (220) of the assembly (200) is disclosed. The tool (100) comprises a ring support (130), a first wrench (110), coupled to the ring support (130), a worm ring (140), rotationally coupled to the ring support (130), a second wrench (120), coupled to the worm ring (140), and a worm screw (150), rotationally coupled to the ring support (130) and in mesh with the worm ring (°).

Abstract: A drill bushing for a drill unit. In one embodiment, the drill bushing includes a base member having an upper surface, a lower surface configured to rest on a workpiece having a pilot hole, and a retaining member that projects from the lower surface of the base member. The retaining member has a cylindrical outer diameter that fits within the pilot hole. The drill bushing further includes a drill hole that passes from the upper surface of the base member through the retaining member to provide a passage for a drill bit. The drill bushing further includes an expandable slit that passes through the base member and the retaining member to the drill hole, and an adjustment member configured to expand the expandable slit to increase the cylindrical outer diameter of the retaining member within the pilot hole.

Abstract: A drill bushing for a drill unit. In one embodiment, the drill bushing includes a base member having an upper surface, a lower surface configured to rest on a workpiece having a pilot hole, and a retaining member that projects from the lower surface of the base member. The retaining member has a cylindrical outer diameter that fits within the pilot hole. The drill bushing further includes a drill hole that passes from the upper surface of the base member through the retaining member to provide a passage for a drill bit. The drill bushing further includes an expandable slit that passes through the base member and the retaining member to the drill hole, and an adjustment member configured to expand the expandable slit to increase the cylindrical outer diameter of the retaining member within the pilot hole.

Abstract: A fastener for fastening a drill jig to overlapping work pieces and clamping the overlapping work pieces for facilitating accurate drilling of the overlapping work pieces including a fastener body and a damper assembly operatively connected to the fastener body. The damper assembly is configured to enable application of a first load to the drill jig, and the fastener body is configured to enable application of a second load to the overlapping work pieces when the fastener fastens the drill jig to the overlapping work pieces. The first load is less than the second load. The first load is sufficient to hold the drill jig to the overlapping work pieces during drilling but without causing significant deformation of the drill jig. The second load is sufficient to reduce the formation of burrs during drilling of a hole through the overlapping working pieces.

Abstract: A fastener for fastening a drill jig to overlapping work pieces and clamping the overlapping work pieces for facilitating accurate drilling of the overlapping work pieces including a fastener body and a damper assembly operatively connected to the fastener body. The damper assembly is configured to enable application of a first load to the drill jig, and the fastener body is configured to enable application of a second load to the overlapping work pieces when the fastener fastens the drill jig to the overlapping work pieces. The first load is less than the second load. The first load is sufficient to hold the drill jig to the overlapping work pieces during drilling but without causing significant deformation of the drill jig. The second load is sufficient to reduce the formation of burrs during drilling of a hole through the overlapping working pieces.

Abstract: A tool that facilitates deburring interfaces in any stack orientation when access is limited to one side of the structure. The deburring blade has the capability to enter drilled holes and remove metallic burrs from mixed material interfaces regardless of stack orientation, i.e., metallic entrance or exit burrs within the stack. The blade design incorporates a slotted feature that hinges on a steel pin. The slot orientation is parallel to the metallic interface of the stackup. The resultant forces of metal material removal are reacted by the walls of the slot, allowing removal of metal material on either the front or back side of the blade tip.

Abstract: An apparatus may comprise a rail system, a multi-axis carriage, a tool module, and a controller. The rail system may be capable of being attached to a surface on a structure. The multi-axis carriage may be coupled to the rail system. The multi-axis carriage may be capable of moving along the rail system and moving a riveting tool in axes relative to the surface. The tool module may be capable of being removably coupled to the multi-axis carriage. The tool module may comprise a frame and may be capable of receiving the riveting tool. The controller may be capable of controlling movement of the riveting tool to a number of locations on the surface of the structure and may be capable of causing the riveting tool to install a number of rivets in the number of preselected locations in response to a signal.

Abstract: An alignment apparatus and method for aligning work pieces. The alignment apparatus includes a base member and at least on adjustable leg that extends from the base member. The alignment apparatus additionally includes a vacuum plate mounted to the adjustable leg. The alignment apparatus also has a an actuator mounted to the base member wherein the actuator includes a shaft extending therefrom. The alignment apparatus includes an attachment member connected to the shaft.

Abstract: An apparatus may comprise a rail system, a multi-axis carriage, a tool module, and a controller. The rail system may be capable of being attached to a surface on a structure. The multi-axis carriage may be coupled to the rail system. The multi-axis carriage may be capable of moving along the rail system and moving a riveting tool in axes relative to the surface. The tool module may be capable of being removably coupled to the multi-axis carriage. The tool module may comprise a frame and may be capable of receiving the riveting tool. The controller may be capable of controlling movement of the riveting tool to a number of locations on the surface of the structure and may be capable of causing the riveting tool to install a number of rivets in the number of preselected locations in response to a signal.